US6386585B1

US6386585B1 - Roll bar

Info

Publication number: US6386585B1
Application number: US09/697,253
Authority: US
Inventors: Hartwig Muller; Robert Schweier
Original assignee: ISE Innomotive Systems Europe GmbH; Blechformwerke Bernsbach GmbH
Current assignee: ISE Innomotive Systems Europe GmbH; Blechformwerke Bernsbach GmbH
Priority date: 1998-04-22
Filing date: 2000-10-26
Publication date: 2002-05-14
Anticipated expiration: 2019-04-22

Abstract

A roll bar for vehicles, in particular for topless motor vehicles, which can be fixedly or retractably attached to the vehicle. The roll bar is of a shell type construction having at least one main substantially flat surface provided with shaped convex portions having shape, size and geometrical arrangement to withstand a plurality of different load directions and/or kinds of load acting on it in the event of an accident.

Description

This application is a continuation-in-part of application Ser. No. 09/298,094 filed Apr. 22, 1999, now U.S. Pat. No. 6,179,327 the contents of which are incorporated herein.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention refers to a roll bar of the kind provided on topless road vehicles for protecting vehicle occupants.

2. Description of Related Art

Roll bars for protecting vehicle occupants in the case of a roll-over accident are known not only in the field of motor racing but also for topless road vehicles or convertibles (cabriolet or roadster). The roll bar can be associated with only one vehicle occupant 1 or bridge the width of the vehicle, to protect two occupants sitting side by side. The roll bar is either fixedly installed or it is abruptly raised into position and locked in place in a critical driving situation. Known roll bars consist of a U-shaped hollow tube, made of steel or light metal, having fastening points formed thereon. Load limits up to which the roll bar has to resist are predetermined by motor vehicle manufacturers for specific and typical cases of load and load directions. The main types of loads are a pressure-load acting on an apex region from above and a bending-load acting transversely to a plane defined by the roll bar. Fracture resisting requirements for the bending-load is normally less than half the fracture resisting requirements for the pressure-load. When known roll bars, consisting of a metal tube, fulfill the bending-load requirements, they are unnecessarily oversized, approximately by a factor of two, for the pressure-load requirements. Furthermore, the known tubular roll bars are heavy. The high weight requires a stable fastening to the vehicle body or, in the case of a retractable roll bar, a powerful retraction driving mechanism. In accidents where the cross-section of the tube of known roll bars is opened by abrasion, due to the fact that the vehicle slides on the roll bar, the load requirements are no longer fulfilled.

SUMMARY OF THE INVENTION

It is the object of the present invention to provide a roll bar of the type to protect occupants of a topless road vehicle which is substantially less heavy than known roll bars and whose structural design is load-oriented without being over-dimensioned for one type of load.

According to the present invention, this object is achieved by turning away from the tubular construction and using a shell construction with unitary convex portions in a substantially flat main surface, which makes it possible to provide the roll bar with an optimum load-oriented structural design, and a substantial amount of weight reduction in relation to tubular roll bars. Materials which are suitable for the roll bar of the shell-construction type are, preferably, a fibrous composite material of the kind being generally used e.g. in the field of motor racing; and also sheet steel, light-metal sheets or some other planar composite material. Modern manufacturing techniques in combination with FEM calculation of anticipated forces permit an exact load-oriented formation of the roll bar, i.e. the roll bar can be adapted to the requirements made by motor vehicle manufacturers with regard to the pressure loads and bending loads, without any necessity of over-dimensioning for one of said loads. When the advantages of shell construction are utilized consistently, a substantial amount of weight is saved, whereby it is possible to use a simpler, less heavy fastening means to the vehicle.

The roll bar of the invention is implemented as a one-piece, either single-shell component or double-shell component, with the load requirements being fulfilled in an optimum manner by the convex portions formed in the shell.

The convex portions of the main substantially flat surface of the shell are adapted to load assumptions from the very beginning, e.g. by FEM calculations with material characteristics, material thicknesses and the like. The shell comprises only the amount of material which is necessary for the respective loads, thus a maximum amount of weight is saved.

Some motor vehicle manufacturers prescribe that, in the case of an accident in which the vehicle, when rolling over, slides on the roll bar, the requirements with regard to pressure and bending loads still have to be fulfilled when abrasion occurs due to sliding friction. This requirement is fulfilled for the shell-construction roll bar by an upper abrasion zone, and/or by anti-attrition inserts. In this connection, it is preferred to provide the abrasion zone of the shell as an energy-absorbing deformation area and to attach an anti-attrition insert to the top, if desired, or, better, to provide such an insert below the abrasion zone so that it is not directly exposed to the impact forces from the very beginning of an accident involving sliding.

Up to 50% or more of the weight of a shell-construction roll bar, which is as efficient as a tubular roll bar, can be saved when said shell-construction roll bar consists of a fibrous composite material. Fibrous composite materials can be processed easily and in an ecologically harmless manner and they can be re-used later on. Glass fibers, carbon fibers or aramid fibers, with weft and warp threads in the layers of fabric, are excellently suitable materials. Plastic matrix may consist of a thermoplastic or a duroplastic material. Polyamide or PET are particularly suitable for this purpose. It is also possible in practice of the invention to use a metal foam as a matrix for fixing the layers of fabric. Thermoplastic materials have the additional advantage of being especially abrasion-resistant because these materials partially plasticize under the influence of friction (heat) and a lubricating effect is produced.

An easy and highly true-to-shape production of the roll bar is possible, even in the case of difficult cross-sectional shapes, by thermal forming, e.g. pressing under the influence of heat.

Edge regions of the shell contribute to the reinforcement of the roll bar, provided that they are implemented as convex portions. Flanges formed on the edge regions serve to connect shells in the case of a multi-shell roll bar.

Convex portions formed in the main substantially flat surface serve to optimize absorption of loads on the roll bar, the cross-section, orientation and shape of convex portions are optimized precisely with respect to load assumptions in an expedient manner by FEM calculations.

Convex portions formed in the main substantially flat surface serve to optimize absorption of loads on the roll bar. The cross-section, orientation and shape of convex portions are optimized precisely with respect to load assumptions in an expedient manner by FEM calculations.

An intentional symmetry or asymmetry of the convex portions relative to a central vertical plane of the roll bar contributes to optimize the load transmittal. In this respect, it should be pointed out that the roll bar can be implemented for taking up pressure centrally, approximately at right angles to the central plane of the roll bar, or for a load direction inclined at an oblique angle from above the center of the vehicle.

In the preferred production technology the convex portions are pressed into the substantially flat main surface from the same side of the main surface; this is especially preferred for a roll bar consisting of two shells. In the case of a single-shell roll bar it would be possible, in practice of the invention, to press the convex portions into the substantially flat main surface, alternately or in groups, from different sides of the main surface so as to increase the stability by means of a broader overall cross-section.

An abrasion zone is provided in an apex region of the shell, such abrasion zone being adapted to be consumed by an abrasion load without impairing the load capacities of the roll bar for the main loads described above. Alternatively, at least one insert of an anti-attrition material can be provided on or in the roll bar.

For optimizing the load absorbing capacity of the roll bar, it is preferred to orient weft and/or warp threads in the layers of fabric in relation to the main load directions so as to achieve a specific load absorbing behavior.

In order to conceal the technical character of the roll bar and/or in order to improve vehicle-occupant protection, an elastic cover can be provided for the roll bar.

When the shell-construction roll bar of the invention is used, fastening means for securing the roll bar in position in the vehicle can be taken into account and the increased stability or stiffness which can be achieved by use of the convex portions can be utilized in an expedient manner.

The substantially flat main surface can also have formed therein apertures for decorative or other reasons; said apertures should be formed in areas where little stress occurs under load.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present invention are explained in more detail below making reference to the following drawings, in which:

FIG. 1 shows a perspective schematic representation of a symmetric single-shell roll bar of the invention;

FIG. 2 shows a perspective schematic representation of an asymmetric single-shell roll bar of the invention;

FIG. 3 shows a perspective schematic representation of a two-shell roll bar of the invention;

FIG. 4A shows a cross-sectional configuration for a single-shell construction of the roll bar of the invention in a section plane indicated as IV—IV in FIG. 1;

FIGS. 4B and 4C show a cross-sectional configuration for two-shell construction of the roll bar of the invention in a section plane indicated as IV—IV in FIG. 1 for shell S;

FIGS. 5 and 6 show respectively a front view of a symmetric and an asymmetric roll bar of the invention, each having a specific fiber orientation in layers of fabric;

FIG. 7 shows a front view of a roll bar of the invention provided with a cover of foam material;

FIGS. 8 and 8A show respectively a front view and an associated side view of a shell-construction roll bar of the invention provided with an abrasion zone;

FIGS. 9A and 9B show respectively a front view and an associated cross-sectional side view of a shell-construction roll bar of the invention with anti-attrition attachments;

FIGS. 10A and 10B show respectively a front view and an associated cross-sectional view of a further embodiment of the anti-attrition attachments of FIG. 9A;

FIGS. 11A and 11B show cross sections through further embodiments of anti-attrition attachments of FIG. 9A;

FIGS. 12A and 12B show cross sections through yet further embodiments of anti-attrition attachments of FIG. 9A;

FIG. 13 schematically shows an embodiment of the invention in perspective having varying shell thicknesses;

FIG. 14 shows a cross-sectional view of the embodiment of FIG. 13 taken along interrupted line XIV-XIV;

FIG. 15 shows a perspective schematic representation of a second embodiment of a single-shell roll bar of the invention;

FIG. 16 shows a perspective schematic representation of the single-shell roll bar of FIG. 15 in a direction indicated by arrow XVI;

FIG. 17 shows a perspective schematic representation of the single-shell roll bar. of FIG. 15 in a direction indicated by arrow XVII;

FIGS. 18-22 show cross-sectional views of the single-shell roll bar of FIG. 15 in section planes indicated as XVIII—XVIII, XIX—XIX, XX—XX, XXI—XXI and XXII—XXII respectively in FIG. 17;

FIG. 23 shows a cross-sectional view of the single-shell roll bar of FIG. 15 in a section plane indicated as XXIII—XXIII;

FIG. 24 shows a perspective schematic representation of a top apex portion of the single-shell roll bar of FIG. 15 equipped with further components;

FIG. 25 shows a perspective schematic representation of a base portion of the single-shell roll bar of FIG. 15 equipped with further components; and

FIG. 26 shows a perspective schematic representation of a two-shell roll bar.

DETAILED DESCRIPTION OF THE INVENTION

In FIG. 1, a shell construction roll bar B, which is substantially mirror-symmetrical with regard to a central plane N has a U-shaped configuration. Roll bar B in FIG. 1 is a one-piece shell S, which in a preferred embodiment consist of a fibrous composite material K (or in other embodiments of a sheet material or some other planar composite material), and is provided with a substantially flat main surface H delimited by an inner edge region 1, which terminates in a flange 2, and by an outer edge region 3, which terminates in a flange 4. Said substantially flat main surface H has shaped convex portions F formed therein so as to impart the necessary strength to the roll bar B. Apex region 8 of the roll bar B is, for example in an accident, subjected to a vertical pressure load D essentially in a direction along said substantially flat main surface H. Said vertical pressure load is effective also approximately along the central plane N. The roll bar can also be subjected to bending moments effective in the direction of double arrow A. In both cases of pressure and bending loads, the roll bar B must resist up to certain load limits.

The shaped convex portions F formed in the substantially flat main surface H of shell S are the

edge regions

1 and 3 with their flanges 2, 4, which have already been mentioned, and a plurality of

convex portions

5A, 5B, 9A, 9B, and 13 which are all formed into the substantially flat main surface H from the same side of said main surface H in a preferred embodiment and which, at least in such embodiment of FIG. 1, are distributed in a substantially mirror-symmetrical arrangement with regard to central plane N. In each leg L_Aand L_Bof the roll bar B a comparatively deep and broad convex portion (5A and 5B) having a semicircular cross-section begins at

leg end

6A or 6B and extends along the outer edge region 3 up to and beyond the level of an inner bend 10 in the direction toward the apex region 8, and ends within the edge region 3 at 7A or 7B. Further

convex portions

9A and 9B near the top of each leg is bent at an obtuse angle and a lower end 11 thereof extends into a V-shaped area between the

convex portions

5A or 5B and the inner edge region 1 below the inner bend 10. An upper end 12 of each

convex portions

9A and 9B is located within the outer edge region 3 and the inner bend 10, on a higher level towards apex region 8 than the

ends

7A or 7B of the

convex portions

5A and 5B.

Ends

7A and 7B of

convex portions

5A and 5B are located at the bend of

convex portions

9A and 9B, said

convex portions

9A and 9B extending first at an oblique angle upwards towards the central plane N and then, along a rounded curve, away from central plane N at an oblique angle outwards. The convex portions are arranged on both sides of central plane N. Between

convex portions

9A and 9B, a central, essentially straight convex portion 13 is provided whose lower end 14 is located approximately above the inner bend 10 and whose upper end 15 is located close to the outer edge region 1 of the apex region 8. The

edge regions

1 and 3 are curved away from the substantially flat main surface H in a round, equidirectional curvature. Main surface H has formed therein a plurality of fastening points 16. The main surface H may also have formed therein at least one free aperture (not shown).

It is preferred that the fibrous composite material K from which the one-piece shell S is formed consist of so-called prepregs, i.e. layers of fabric impregnated with a plastic material with such fabric consisting of glass fibers, carbon fibers or aramid fibers, which are interwoven as weft threads and warp threads. Shell S according to FIG. 1 is formed as a unitary shell from a substantially flat shell blank e.g. in a heated pressing mould under the influence of pressure and temperature acting on the shell blank which is preheated. The shell blank can consist of several layers if desired. Due to the pressing, the layers of fabric are embedded into a plastic matrix, and the configuration with convex shaped portions F in the main substantially flat surface H, which can be seen in FIG. 1, is obtained. The main surface H is substantially flat. It is, however, possible to carry out the process of the invention by imparting a spatial curvature to said main surface H in one direction or the other, as outlined by the network of lines in FIG. 1.

In FIG. 2 an asymmetric roll bar B (or a symmetric roll bar B with an asymmetric load bearing behavior) is depicted. The convex portions F of the one-piece shell S are essentially three slightly curved

convex portions

18, 20 and 21 and outer edge region 3 which is rounded. In the area of inner bend 10, an inner edge 17, which becomes increasingly flat is indicated. The inner edge region 1 according to FIG. 1, is curved relative to the substantially flat main surface H, and such type curve can be provided in the case of this embodiment, (FIG. 2), as well. The main surface H has formed therein two fastening points 16 per leg of the roll bar B; if desired, these fastening points 16 may be provided with hole reinforcements, which can be integrated in the main surface H or formed relative thereto. The longest of the three convex portions, 18, extends between the two other convex portions and begins at a left lower leg, passes inner bend 10, and extends towards apex region 8 in such a way that it is approximately oriented towards a point of introduction of vertical pressure load D (asymmetrical introduction of pressure) and also towards an influence sphere of bending moments in the directions of double arrow A. Convex portion 18 is slightly curved around the inner bend 10. In a sickle shaped area between the convex portion 18 and the outer edge region 3 in the left leg of the roll bar B a convex portion 20 begins and extends substantially parallel to convex portion 18 and is also oriented towards apex region 8. A third convex portion 21 begins in the right leg between the fastening points 16, extends around the inner bend 10 with a slight curvature and ends at a small distance from convex portion 18 at 22, said convex portion 21 and said convex portion 18 define an angle of approx. 80°.

Roll bar B in FIG. 3 is produced from two shells S_Aand S_Bof fibrous composite material K which are e.g. joined by an adhesive with shell S_Acovering the area of the lower shell S_Bbetween inner bend 10 and apex region 8. Each shell, S_A, S_B, has a main surface H and shaped convex portions F. In the case of the upper shell S_A, said convex portions F are essentially only the bent outer edge region 23 which terminates in a flange that is connected to flange 4 of outer edge region 3 of the lower shell S_B. The lower shell S_Bhas shaped convex portions F which are similar to those provided in the embodiment of the shell S of FIG. 1. Convex portions 5, which are formed in the main surface H of shell S_B, can be seen in FIG. 3.

FIGS. 4A, 4B and 4C are outlines of embodiments of the roll bar in planes as indicated in FIG. 1 at IV—IV, that is slightly above inner bend 10 of the embodiments. FIG. 4A is a single-shell component with shaped convex portions F formed in the main surface H of the shell S. In FIG. 4B the roll bar is a double-shell component consisting of shell S_Bprovided with the shaped convex portions and of another shell S_Awhich is deformed only in the edge region (two-shell construction). In FIG. 4C the roll bar consists of two shells S_Aand S_Bwhich are either implemented symmetrically (as in the case of FIG. 1) or nonsymmetrically, both shells S_Aand S_Bbeing provided with shaped convex portions F. In the case of the two-shell construction, the shells can be joined by an adhesive or welded together. In FIG. 4A it is indicated that roll bar B has a protective and/or decorative cover 26 of plastic material, foam material or the like.

FIG. 5 indicates that layers of a fabric G in a plastic matrix M contain weft and

warp threads

24, 25 which extend at oblique angles α, β relative to the central plane N (see FIG. 1) so that the forces on the roll bar are taken up in an optimum manner. The angles α and β range from 20 to 40°, and the preferred value for said angles is approx. 25°.

FIG. 6 shows a roll bar B which is asymmetrical with respect to a plane N which extends approximately vertically in a vehicle body. Weft and

warp threads

24, 25 of the layers of fabric G or of at least one layer of fabric are oriented such that an angle γ, which is approx. 25°, is obtained between the weft threads and the central plane N, and the warp threads extend approximately parallel to plane N. The angles indicated in connection with FIGS. 5, 6 are only examples. The essential point is that the force take-up behavior of the roll bar B can be influenced by the orientation of the weft and/or warp threads relative to force introduction directions. It is possible in carrying out the invention to choose identical thread orientations or different thread orientations in each layer of fabric G.

In FIG. 7 roll bar B is shown with a cover 26 (foam padding, upholstery or elastomer) with an outer bead. The legs of the roll bar B are secured to the vehicle body or connected to a drive means (not shown) for retracting the roll bar B or for pivoting it to an upright position. The cover 26 covers most of a possibly untreated surface (for aesthetic reasons, for protecting the vehicle occupants, or as a protection against atmospheric effects).

FIGS. 8A and 8B illustrate an abrasion zone 28 provided above a predetermined supporting height h of roll bar B, which is preferably formed of a fibrous composite material as a shell-construction component; under the influence of friction forces R (indicated by broken lines), abrasion zone 28 can be consumed without jeopardizing the pressure and bending-load absorbing properties of the roll bar B. In the associated side view FIG. 8B, it can be seen that the abrasion zone 28 can have a shaped structure 29 which is formed by a bend in the shell so as to be able to consume the largest possible amount of friction force and/or so as to serve as a deformation zone to be sacrificed.

In FIGS. 9A and 9B it is indicated that shell S or two interconnected shells (FIG. 9B) of roll bar B have inserted at least one insert 30 of anti-attrition material, e.g. steel, ceramics, a braided fiber fabric, light metal or plastic material which slides well or which is equipped such that it has good sliding properties. The insert 30 may be integrated (embedded) in the shell S. It is also preferred that the insert 30 be positively secured in position on a shoulder 31 or in a pocket of the shell so that it will remain on said shell under the influence of abrasion and impact forces. It is possible in practice of the invention to provide such inserts at both outer sides of the roll bar—either a one-piece insert on each side or a plurality of individual inserts so as to save weight. The insert 30 should be provided on a slightly lower level (as shown in FIGS. 9A and 9B) so that it will only become effective after the abrasion zone is worn away and so that it will not be directly exposed to the impact force of the ground from the very beginning in event of an accident.

FIGS. 10A and 10B illustrate an attachment 30 attached, e.g. by means of rivets 33, to at least one outer side of roll bar B, or several attachments, which are separated by intermediate spaces. At top edges, the attachments can be covered by a decorative cover 32 or a cover 32 having good sliding properties, or they may be covered by the abrasion zone 28 outlined in FIGS. 8A and 8B.

FIGS. 11A and 11B show cross-sectional views of shells of roll bar B in which attachment 30 is put over the shell (in apex region 8) in the fashion of a cap 34 having a U-shaped cross-section (FIG. 11A) or with abrasion zone 29, 28 (see FIG. 8B) combined with a cap 35 defining attachment 30.

FIGS. 12A and 12B, two further embodiments of securing an anti-attrition attachment 30 in position on shell S of roll bar B are indicated. In the representation of FIG. 12A, attachment 36 encompasses the apex region of the roll bar like a cap and one supporting leg thereof extends inwards through a wall so that the attachment will not come off under load. This is a fastening mode which is preferred for a roll bar consisting of two shells. In the representation of FIG. 12B, a sacrificial abrasion zone 29 is combined with attachment 37, which is attached in an inner bend of the shell below the abrasion zone, said attachment 37 fits closely to the round corner and is held therein e.g. by rivet connection 33 so that said attachment cannot separate itself from the shell S under load.

With such shell construction, a load-adapted geometric structural design of various roll-bar concepts can be achieved. Also in the case of bending forces, the structural design is adapted to the bending moments in question, oversized dimensions for the vertical pressure load being avoided. The production of each shell need not necessarily be carried out by thermal forming (pressing) described above, as it is possible to use the laying-up, the RTM, the SMC method or other methods. Cover 26, e.g. a foam padding, outlined in FIG. 7 provides improved vehicle-occupant protection, e.g. in the case of blows to the head, and permits a desired optical or decorative effect to be achieved. The cover can have applied thereto a special top layer producing e.g. the optical effect of a carbon-fiber reinforcement. Fastening points 16 (FIGS. 1 and 2) can be reinforced by sheet-metal elements so as to reduce compression and to improve the distribution of forces in the roll bar. In comparison with tubular roll bars, the shell geometry can be optimized precisely by means of its shaped convex portions with regard to the anticipated loads. The weight of the roll bar consisting of the fibrous composite material K is only approx. 1.2 kg, whereas a typical steel-tube roll bar has a weight of about 2.8 kg. In the case of roll bars that can be folded down or pivoted to an upright position, roll bars of the invention will result in shorter positioning times for the roll bar (more safety), and a drive mechanism for positioning the bar can be simplified and designed such that it is less heavy. The shells of the roll bar can more easily be incorporated into the design of the passenger compartment and of the skin of a vehicle from the structural as well as from the decorative point of view. Each shell can be designed comparatively freely under ergonomic and/or aesthetic, aspects. When a steel-tube roll bar is used, abrasion can change and weaken the cross-sectional dimensions, whereby the fracture strength will be reduced substantially. In the case of roll bars having the structural design described in the present application, abrasion does not have any significant influence on the fracture strength. Shell construction can also be used for roll bars bridging the whole width of the vehicle as well as solely one occupant. In this case, it may, however, be expedient to produce the roll bar by combining a plurality of separately produced shell components or/and tubular components. The energy absorption behavior is predeterminable and more advantageous than in the case of tubular roll bars because the impact occurring is less violent and less dangerous for the passengers because of the damped or delayed energy absorption.

An embodiment of FIGS. 13 and 14 differs from the embodiment of FIG. 1 in that the three shaped convex portions having a central location have been omitted. In order to obtain sufficient stiffness in the embodiment illustrated in FIGS. 13 and 14, the wall thickness of the shell has been increased in the upper central portion of the roll bar, as indicated at V in FIGS. 13 and 14. FIG. 14 is a sectional perspective view of the embodiment of FIG. 13 with the section taken in a plane indicated by interrupted line XIV—XIV of FIG. 13.

Another embodiment of a single-shell roll bar of the invention is shown in FIGS. 15 to 23. Roll bar B in FIGS. 15 to 23 comprises a single shell S made from fibrous composite material K. The shell is integrally formed and has a peripheral outer edge contour shaped as an inverted “U” with a curved top apex edge portion 38, two leg edge portions 39 extending downwardly from said curved top apex edge portion 38 and a lateral base edge portion 40 interconnecting said leg edge portion 39. The entire inner space of the inverted “U” is filled by the fibrous composite material to form a closed “U”.

The fibrous composite material K consists of so-called prepregs, i.e. layers of woven fabric impregnated with a plastic material. The woven fabric consists of weft threads and warp threads made of glass fibers, carbon fibers or aramid fibers, or mixtures of such fibers. The weft and warp threads have a predetermined angular orientation in relation to the two leg edge portions 39. The plastic material is either thermoplastic or duroplastic material. In case of thermoplastic the material is polypropylene, polyamide or polyethylene terephthalate. Shell S of the single shell roll bar B of FIG. 15 is formed from a substantially flat shell blank, e.g. a stack of several prepregs, e.g. in a heated pressing mould under the influence of pressure and temperature. Due to the temperature influence the impregnation of the prepregs is melted until finally the fabric layers are fully embedded in a plastic matrix. The press mould forms the shell blank into the desired shell form. The shell then is cooled down and solidified and if necessary, cut along the peripheral edge contour.

Shell S of FIGS. 15 to 23 has a substantially flat edge flange 41 extending with essentially constant basic thickness x (FIG. 17) along said curved top apex edge portion 38 and along both leg edge portions 39. Between both leg edge portions 39 and within the edge flange 41 shell S has at least one convex portion F. The convex portion F together with edge flange 41 is adapted to absorb a portion of the loads encountered onto the single shell roll bar B in the event of an accident of a topless vehicle, e.g. equipped behind each seat with the single shell roll bar B of FIG. 15 or with a two-shell roll bar B as shown in FIG. 26. The respective roll bar B can be mounted stationarily in the vehicle body. Alternatively, the roll bar can be kept in a retracted position within a car body mounted guiding structure and can be rapidly pushed upwardly by an actuator and finally locked in its active position in the event of an accident. The embodiment of the roll bar shown in FIGS. 15 to 26 is intended for use in a guiding structure of a vehicle to be pushed upwardly only in case of a critical driving condition. Slightly modified, the roll bar of FIGS. 15 to 26 instead could be mounted stationarily in a vehicle. In any case, the top apex portion 38 is the portion of the roll bar where the load will act during an accident, while the roll bar is supported in its lower region.

FIGS. 15, 16, 17 and 19 it is shown that at least a part of the substantially flat edge flange 41 is defining a substantially flat main surface H of the shell S. Within edge flange 41 there is provided a first convex portion F in the form of a longitudinally extending portion 47 which is raised in relation to main surface H and extends from lateral base edge portion 40 in a longitudinal direction between both leg edge portions 39 towards curved top apex edge portion 38. Raised portion 47 is connected by rounded transitions with edge flange 41. In the middle of raised portion 47 a generally triangular depressed portion 44 is formed. In the vicinity of portion 44 two elongated convex portions 45 of rounded cross-section are arranged in a V-configuration such that they diverge towards the curved top apex edge region 38, extend along raised portion 47 and terminate in edge flange 41. Close to lateral base edge portion 40 a further convex portion 46 is formed into raised portion 47 forming a rounded support surface 48.

In relation to main surface H, which is parallel to the plane defined by the “U” peripheral edge contour of shell S, raised portion 47 is formed upwardly from main surface H, portion 44 is a depression, portions 45 are protruding beyond the upper surface of raised portion 47, and portion 46 is a depression in the surface of raised portion 47.

Along edge flange 41 there is provided at least one elevation 42 and at least one recess 43. The elevation forms a boundary of the recess in the direction along leg edge portions 39. The elevation and

recess

42, 43 are rounded or, as alternatively shown at 42′, 43′ of FIG. 17, stepped.

Elevations and recesses 42, 43 serve to create a positive form-fit active in the direction of the main surface between two shells S of FIGS. 15 to 23 joined together flat to flat with their edge flanges 41 (as shown in FIG. 26). Recesses and elevations 42′, 43′ may serve the same purpose, namely to create a form-fit in case of a two-shell roll bar B as shown in FIG. 26, but also might have another purpose, namely to provide the necessary mounting space for further components and even to form a retainer for such a component (as shown in FIG. 25).

FIGS. 18 to 22 clearly show that the thickness within convex portion 47 in section planes XVIII—XVIII and section plane XXII—XXII is substantially equal to the basic thickness x of the edge flange 41, while the thickness of convex portion 47 in-between the two section planes varies to bigger values, even to a multiple of basic thickness x, e.g. a value y corresponding to the threefold basic thickness x. The thickness variation may be gradual or in steps. Along the edge flange the basic thickness X is maintained essentially constant. Generally, edge flange 41 is parallel to main surface H, except in the regions close to lateral base edge portion 40, where the outer edge of edge flange 41 is bent upwardly at 41 a.

In FIG. 24 as an additional functional component of shell S for the single shell roll bar of FIG. 15 or the two-shell roll bar B of FIG. 26, in an anti-abrasion zone Z, at least one anti-attrition-attachment 49 is provided. Attachment 49 may be made of metal and is seated in a recess 51 formed in edge flange 41 at curved top apex edge portion 38. Recess 51 is formed in the vicinity of the rounded elevations and recesses 42, 43 and is intended for co-action with respective recesses and elevations in the other of the two shells which will be put onto edge flange 41 for providing the two-shell roll bar B as shown in FIG. 26. Both shells S as combined in a two-shell roll bar do not necessarily need to be substantially identical or fully identical but can also be non-identical. Identical shells are of advantage for manufacturing reasons. Attachment 49 is secured in place either by plastic material of the fibrous composite material K, as used in the shell S, engaging into holes 50 provided in attachment 49, or instead, rivets or other fastening elements are used to secure attachment 49 in place in shell S. As an additional stiffening element a tube structure 54 is provided which is fixed to the shell S by suitable means and which furthermore is in positive engagement with the rear part of attachment 49. For example, stiffening structure 54 is bonded to the inner surface of each of the shells S.

In FIG. 25 stiffening structure 54 is held by suitable means in supporting surface 48 of convex portion 46. At both sides of shell S, and close to lateral base edge portion 40, a metallic anchor plate 56 is mounted by means of several fastening elements 58 which might be rivets or fastening screws or plastic material joining the anchor plates 56 with the respective shell S. Each anchor plate 56 has a hook-shaped anchor 57 which is protruding sidewardly from roll bar B. Anchors 57 are used to define the active position of the pushed out roll bar B by co-action with a stop of the guiding structure of the roll bar (not shown). Furthermore a rack element 55 (FIG. 26) is placed on edge flange 41 (along each leg edge portion 39) which serves to co-act with a not shown catching element in order to support the pushed out roll bar in its active position in relation to the not shown guiding structure.

In cases that two identical, substantially identical or non-identical shells S are joined at their respective edge flanges 41 as shown in FIG. 26, the connection can be made by welding, gluing or fastening elements like screws or rivets such that both shells are held in firm contact at their common main surface H and are unable to move in relation to each other, and also due to the form-fits, as explained, achieved between the co-acting regions of the mutually contacting edge flanges 41 of both shells S. In a case that attachment 49 is provided in anti-abrasion zone Z, attachment 49 should be firmly clamped between both shells. Attachment 49 either is flush with the curved top apex edge region 38 or even is protruding beyond the same.

In raised or convex portion 47, in other not shown embodiments, there might be provided several convex elongated portions 45 with dimensions and arrangements adapted to absorb portions of the loads encountered to the roll bar in the event of an accident as optimal as possible in order to protect vehicle occupants. Portion 46 with supporting surface 48 is not necessary in each case. Also, depression 44 could be omitted or could be replaced by a portion of locally increased thickness.

While specific materials, designs and fabricating steps have been set forth for purposes of describing embodiments of the invention, various modifications can be resorted to, in light of the above teachings, without departing from Applicants' novel contributions; therefore in determining the scope of the present invention, reference shall be made to the appended claims.

Claims

What is claimed is:

1. A roll bar for topless motor vehicles, to provide protection to a vehicle occupant from pressure, bending, and abrasion loads in event of an accident, comprising

at least one integrally formed shell having a peripheral edge contour shaped as an inverted and closed “U” with a curved top apex edge portion, two leg edge portions extending downwardly from said curved top apex edge portion and a lateral base edge portion interconnecting both leg edge portions, with a substantially flat main surface parallel to a plane defined by said inverted “U”-shaped edge contour,

at least one convex portion formed in said main surface,

each said convex portion having a shape, size and geometrical arrangement within said peripheral edge contour adapted to absorb a portion of the loads encountered in event of an accident,

said shell consisting of a fibrous composite material of a plurality of layers of fiber fabric embedded in a plastic matrix,

said fiber fabric selected from the group consisting of:

a) glass fibers

b) carbon fibers

c) aramid fibers and

d) blends of any of the above,

said plastic matrix being a thermoplastic or duroplastic material.

2. A roll bar according to claim 1, wherein each layer of fiber fabric is a woven fabric consisting of warp and weft threads, said weft and warp threads each having a predetermined angular orientation in relation to said two leg edge portions.

3. A roll bar according to claim 1, wherein the plastic material of said plastic matrix is polypropylene, polyamide, or polyethylene terephthalate (PP, PA, PET).

4. A roll bar according to claim 1, wherein an abrasion zone is integrated into said curved top apex edge portion of said shell, said abrasion zone comprising at least one anti-attrition insert.

5. A roll bar according to claim 1, wherein a continuous, substantially flat flange of said shell extends along said curved top apex edge portion and along said two leg edge portions, said edge flange generally defining said main surface of said shell,

said at least one convex portion being bounded by said edge flange and extending from said lateral base edge portion in a longitudinal direction between both leg edge portions into said edge flange along said curved top apex edge portion.

6. A roll bar according to claim 5, wherein said edge flange is essentially parallel to said main surface and of substantially constant basic thickness measured perpendicular to said main surface,

said at least one convex portion bounded by said edge flange having a thickness at least corresponding to said basic thickness and gradually varying in thickness in the longitudinal direction of said shell from said lateral base edge portion towards said top apex edge portion.

7. A roll bar according to claim 5, wherein said at least one convex portion bounded by said edge flange contains further elongated convex portions with a rounded cross-section, with such convex portions being longitudinally directed towards said curved top apex edge portion with one longitudinal end of each elongated convex portion merging into said edge flange.

8. A roll bar according to claim 7, wherein said elongated convex portions have a shape in a longitudinal direction selected from the group consisting of:

a) straight,

b) curved, and

c) an obtuse angle.

9. A roll bar according to claim 5, comprising two substantially identical shells joined together at their respective edge flanges by welding, gluing, screws or rivets.

10. A roll bar according to claim 9 wherein said two shells each contains in an edge flange section along at least one of said two leg edge portions, at least one recess bounded in the direction of the respective leg edge portion by a rounded or stepped elevation, said elevation of the edge flange of one of the two shells being situated within the recess of the other of the two shells with a positive form-fit co-action in the direction of said main surface.

11. A roll bar according to claim 5, comprising two shells, which are different from each other, joined together at their respective edge flanges by welding, gluing, screws or rivets.

12. A roll bar according to claim 11, wherein said two shells each contains in an edge flange section along at least one of said two leg edge portions, at least one recess bounded in the direction of the respective leg edge portion by a rounded or stepped elevation, said elevation of the edge flange of one of the two shells being situated within the recess of the other of the two shells with a positive form-fit co-action in the direction of said main surface.

13. A roll bar according to claim 5, wherein said at least one convex portion bounded by said edge flange has formed therein a generally triangular shaped depressed portion.

14. A roll bar according to claim 13, further comprising, in said at least one convex portion bounded by said edge flange, in the vicinity of said depressed portion,

two elongated convex portions of rounded cross-section, arranged in a V-shaped configuration such that they diverge toward the curved top apex region, extend along the convex portion bounded by said edge flange, and terminate in the edge flange.

15. A roll bar according to claim 5, further including at least one anti-attrition attachment seated in a recess formed in the edge flange at said curved top apex edge portion of the shell.

16. A roll bar according to claim 15, further including

a tube structure stiffening element fixed at one end to the base portion of the shell and at the opposite end in positive engagement with the anti-attrition attachment at said curved top apex edge portion of the shell.